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Welcome to the 2G GT Tech section. Within these hallowed threads you will find many useful and helpful references to many people that came way way way before you, such as Mike P., J. Bradbury, Ross Lapkof, and even Michel Fortier. Many of these people pushed the limits to our knowledge of these cars and opened up many different possibilities that today we take for granted. Julian, specifically, offered technical reference that was unsurpassed, of which I R.C.S.A.’d a long time ago. Perhaps what you read here will be something that warrants use of your right mouse button as well.
Now many of you have already read the “Change your own clutch” thread. I hope it has helped many of you in turning some of your own wrenches on your car. What follows will be a similar thread, but geared towards a complete KL-03 to KL-ZE Swap. I will try to provide you with as many of the idiosyncrasies as I can remember and/or have solutions to. So sit back, relax, and all you “pro’s” can see if I missed anything
For starters, make sure you have everything before you start anything. Here is a basic list:
The text that you have entered is too long (25656 characters). Please shorten it to 7500 characters long.
Welcome to the 2G GT Tech section. Within these hallowed threads you will find many useful and helpful references to many people that came way way way before you, such as Mike P., J. Bradbury, Ross Lapkof, and even Michel Fortier. Many of these people pushed the limits to our knowledge of these cars and opened up many different possibilities that today we take for granted. Julian, specifically, offered technical reference that was unsurpassed, of which I R.C.S.A.’d a long time ago. Perhaps what you read here will be something that warrants use of your right mouse button as well.
Now many of you have already read the “Change your own clutch” thread. I hope it has helped many of you in turning some of your own wrenches on your car. What follows will be a similar thread, but geared towards a complete KL-03 to KL-ZE Swap. I will try to provide you with as many of the idiosyncrasies as I can remember and/or have solutions to. So sit back, relax, and all you “pro’s” can see if I missed anything
This list will be separated into three sections: removal, maintenance/performance, and prep for install/installation. I will try to keep it as concise as possible
For starters, make sure you have everything before you start anything. Here is a basic list:
- A car with a KL block already in it……that needs the KL-ZE.
- A complete replacement KL-ZE Motor.
- Drain pan capable of collecting up to 8 qt of oil / gear lube.
- A separate container capable of collecting up to 2 gallons of antifreeze / coolant.
- A basic set of hand tools including but not limited to:
- Metric 3/8 drive ratchet set from 8mm to 17mm w/ extension up to 12” (this is about standard)
- Metric ½ drive ratchets in 17, 19, & 23 mm
- Small assortment of Philips and Flat head screwdrivers
- Snub and Long needle nose pliers
- 5# sledge hammer
- Perhaps a 10 # as well
- Center Punch and Chisel Punch
- Metric open/box end wrenches 8mm to 17mm (I prefer the Gear Wrenches)
- Metric Allen set
- Floor jack with 12-15” lift
- Jack stands
- Preferably ½ drive torque wrench
- Make sure you have someplace to do this, preferably a flat driveway or garage if applicable. Also make sure your neighbors will not take offense to you turning their community into their own little slice of Alabama.
- Ample time to accomplish this; my best time on a straight swap (no performance crap “at the same time”) was right at 6 hr.
- You will hurt the day after this so get some Advil or alcohol now.
- Full quantities of replacement fluid:
- 2 oil filters
- 5 quarts of cheap oil
- 5 quarts of Mobil 1
- one gallon of coolant, or 2 gallons of 50/50 pre-mix
- 3 quarts of gear lube; your choice (Red Line, Royal Purple, GM Synchromesh, just regular 75W90
- And finally an Engine Hoist, Cherry Picker, or equivalent
Bear in mind that this is for a manual transmission equipped vehicle; the automatic is slightly different, whereas the transmission will remain in the vehicle
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